Shower base system and installation method thereof

ABSTRACT

A shower base system and installation method thereof. The system includes a shower base with an integrally formed tapered standing sidewall corresponding to each existing structural wall against which the base is installed, and a waterproof membrane covering and extending upwardly along the structural wall from a bottom point at least partially covering the standing sidewall. The system can be installed with the sidewall directly abutting drywall or other outer surface of the structural wall, covered in turn by the membrane with tiling applied thereon, or, alternatively, with the sidewall directly abutting a bottom plate and studs or timbers of the structural wall, with drywall installed over the sidewall and the membrane covering the drywall, and tiling applied on the membrane.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to shower structure and in particular to a shower base system providing secure and effective protection against leaks and an installation method thereof.

2. Description of the Related Art

New residential construction and renovation and remodeling of existing residential properties are major industries worldwide, with the latter becoming even more dynamic when real estate markets render the former economically disadvantageous. A common renovation performed is the installation of additional bathroom facilities, including shower fixtures, in areas previously without such installations.

Unfortunately, in both endeavors, it is required that great care be taken to avoid leakage of water from the shower system into the surrounding structure, specifically walls, floors, and wall-to-floor confluences, with such leakage presenting the potential for major damage, repair of which can incur severe costs.

One primary cause of leakage is lack of integrity in the apparatus used for the floor and lower areas of the shower, areas which, obviously, see the largest concentration of accumulated water. Currently, an abundance of applied technologies address the problems of floor leakage. Other commonly employed installations make use of integrally molded units which minimize the number of joined seams and, accordingly, potential leakage sites. Where joined seams are necessary, the seam is commonly sealed with caulk or other waterproof material. Even so, such sealing means are prone to deterioration with time, giving the leak-proofing at the sites a limited lifespan.

A second, equally problematic source of leak-related damage is water migrating to susceptible areas by capillary action, whereby the water travels beyond leak-proofed areas into those where severe damage is possible.

One method employed to alleviate this problem is to install a leak-proof drywall or waterproof sheeting above a shower base and extending downwards in front of a peripheral lip of the base, with the overlapping area then filled with a suitable sealant.

U.S. Pat. No. 5,371,980 discloses an upstanding peripheral lip surrounding a vacuum-formed shower base, the lip sandwiched between a frame and wallboard or between a wall and tiles. The lip, however, is formed separately from the base and fitted thereinto, presenting yet another potential leakage site.

The procedures described, despite efficaciousness, often require either packing of the corresponding baseplate and studs of the adjoining wall to accommodate the wallboard, or excavation of the studs to form accommodating rebates therein. In both cases, application of a sealant is required to complete the process, an application which can easily provide less-than-adequate leak-proof coverage. As well, the previously mentioned problems with sealant deterioration occur.

Thus, what is called for is a shower base system providing optimum long term leak-proofing with minimal modification of existing structures required.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:

FIG. 1 is a schematic cutaway of a shower enclosure installed with a first embodiment of a shower base system;

FIG. 2 is a detail schematic cross section of the shower base system of FIG. 1;

FIG. 3 is a detail schematic cross section of a second embodiment of a shower base system.

FIG. 4 is a flowchart of a first embodiment of an installation method of a shower base system.

FIG. 5 is a flowchart of a second embodiment of an installation method of a shower base system.

DETAILED DESCRIPTION OF THE INVENTION

Like elements among the drawings bear like labeling, for brevity.

FIG. 1 is a schematic cutaway of a shower enclosure installed with a first embodiment of a shower base system. As shown, the system includes a shower base 100 with an integrally formed standing sidewall 101 corresponding to each existing structural wall against which the base is installed. Here, the system is shown installed against two contiguous structural walls, although the system is equally applicable with a single structural wall or three contiguous walls while remaining well within the scope of the disclosure. A waterproof membrane 102 covers and extends upwardly along the structural wall. Tiling 107 covers the membrane.

FIG. 2 is a detail schematic cross section of a first embodiment of the shower base system of FIG. 1, in which shower base 100 directly abuts drywall or other outer surface 104 applied against baseplate 105 and framing studs 106 of a corresponding structural wall prior to installation of the shower system. Normally, the drywall is of a suitably waterproof material and/or composition. As shown, the integrally formed standing sidewall 101 of the shower base 100 abuts and tightly cojoins against the surface of wallboard 104. Waterproof membrane 103 is applied from a position partway up the corresponding standing sidewall and upwardly along the existing structural wall, adhering intimately to the standing sidewall and drywall or other outer surface of the existing structural wall. Tile or other outer finished material 107 is installed over the floor and walls of the shower enclosure in the common manner.

FIG. 3 is a detail schematic cross section of a second embodiment of the shower base system of FIG. 1, differing from the previous embodiment only in that, here, shower base 100 directly abuts and tightly cojoins against the surface of baseplate 105 and framing studs 106 of the corresponding structural wall. Drywall or other outer surface 104 of the structural wall is disposed over the corresponding standing sidewall, and waterproof membrane 103 begins at the horizontal top floor surface 101 of the shower base and continues upwardly along the structural wall, adhering intimately to the horizontal top floor surface 101 and drywall or other outer surface 104 of the existing structural wall. As in the previous embodiment, tile or other outer finished material 107 is installed over the floor and walls of the shower enclosure in the common manner.

Also provided is an installation method of a shower base system.

FIG. 4 is a flowchart of a first embodiment of an installation method of a shower base system. The shower base system includes a shower base 100 with an integrally formed standing sidewall 101 corresponding to each existing structural wall against which the base is installed. Here, the system is shown installed against two contiguous structural walls, although the system is equally applicable with a single structural wall or three contiguous walls while remaining well within the scope of the disclosure. A waterproof membrane 102 covers and extends upwardly along each structural wall. Tiling 107 covers the membrane.

As shown in FIG. 4, a first embodiment of an installation method of a shower base system includes installing a shower base 100 directly abutting drywall or other outer surface 104, applied against baseplate 105 and framing studs 106 of a corresponding structural wall, prior to installation of the shower system. Normally, the drywall is of a suitably waterproof material and/or composition. As shown, the integrally formed standing sidewall 101 of the shower base 100 abuts and tightly cojoins against the surface of wallboard 104. Waterproof membrane 103 is then applied from a position partway up the corresponding standing sidewall and upwardly along the existing structural wall, adhering intimately to the standing sidewall and drywall or other outer surface of the existing structural wall. Tile or other outer finished material 107 is finally installed over the floor and walls of the shower enclosure in the common manner.

FIG. 5 is a flowchart of a second embodiment of an installation method of a shower base system, differing from the previous embodiment only in that, here, shower base 100 is installed directly abutting and tightly cojoining against the surface of baseplate 105 and framing studs 106 of the corresponding structural wall. Drywall or other outer surface 104 of the structural wall is installed over the corresponding standing sidewall, and waterproof membrane 103 is applied beginning at the horizontal top floor surface 101 of the shower base and continues upwardly along the structural wall, adhering intimately to the horizontal top floor surface 101 and drywall or other outer surface 104 of the existing structural wall. As in the previous embodiment, tile or other outer finished material 107 is installed over the floor and walls of the shower enclosure in the common manner.

As can be seen in the Figures, the at least one standing sidewall 101 is tapered in cross section, from the bottom to the top thereof. The shower base and, commensurately, the at least one standing sidewall, being integrally formed therewith, comprise a composite polyurethane material or other suitably flexible, waterproof material. The shape and inherent adhesive properties of the at least one standing sidewall promote an extremely close fit between the sidewall and the surface it abuts, contributing significantly to the overall waterproofing capabilities of the system. Further, the at least one standing sidewall is of a height sufficient to prevent water rising by capillary action from migrating into the surrounding structures.

In the disclosure, the waterproof membrane comprises a bitumen-like skin in which a fabric or other suitable material has been embedded to provide texturing. The membrane is applied to the requisite surface by means of adhesive, and the application can be enhanced by pre-priming of the surface to be covered. Other materials and compositions providing suitable adhesion and waterproofing qualities may alternatively be employed while remaining well within the scope of the disclosure.

As well, in the embodiments shown, the waterproof membrane extends upwardly to the top of the shower enclosure. Other upper limits of extension thereof are equally applicable to the disclosure, as long as sufficient waterproofing capability is provided thereby.

While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. 

1. A shower base system installed against at least one existing structural wall, the system comprising; a shower base comprising a horizontal top floor surface and at least one standing sidewall corresponding to each existing structural wall; and a waterproof membrane installed prior to any final outer surface material.
 2. The shower base system as claimed in claim 1, wherein the at least one standing sidewall is integrally formed with and substantially perpendicular to the shower base.
 3. The shower base system as claimed in claim 1, wherein the at least one standing sidewall is tapered in profile from a bottom to a top thereof.
 4. The shower base system as claimed in claim 1, wherein the shower base and, commensurately, at least one standing sidewall, being integrally formed therewith, comprise a composite polyurethane material or other suitably flexible, waterproof material.
 5. The shower base system as claimed in claim 1, wherein when the system is applied against two or more contiguous existing structural walls, corresponding contiguous standing sidewalls are confluent at a seamless integrally formed corner.
 6. The shower base system as claimed in claim 1, wherein the at least one standing sidewall is of a height sufficient to prevent water rising by capillary action from migrating into the surrounding structures.
 7. The shower base system as claimed in claim 1, wherein the waterproof membrane is applied from the horizontal top floor surface of the shower base and continues upwardly along each standing sidewall and upwardly along the corresponding structural wall.
 8. The shower base system as claimed in claim 1, wherein the waterproof membrane is applied from a position partway up each standing sidewall and upwardly along the corresponding structural wall.
 9. The shower base system as claimed in claim 1, wherein the waterproof membrane comprises a bitumen-like skin with embedded texturing, applied with adhesive and enhanced by priming the surface to be covered.
 10. The shower base system as claimed in claim 1, wherein the waterproof membrane extends upwardly to the top of the shower enclosure.
 11. The shower base system as claimed in claim 1, wherein the shower base is installed directly abutting drywall or other outer surface of an existing structural wall, the waterproof membrane is applied from a position partway up each corresponding standing sidewall and upwardly along the existing structural wall, adhering intimately to the standing sidewall and drywall or other outer surface of the existing structural wall, and tile or other outer finished material is installed covering the membrane.
 12. The shower base system as claimed in claim 1, wherein the shower base is installed directly abutting a bottom plate and studs or timbers of an existing structural wall, with drywall or other outer surface of the structural wall installed over the corresponding standing sidewall, the waterproof membrane is applied from the horizontal top floor surface of the shower base and continues upwardly along the structural wall, adhering intimately to the horizontal top floor surface and drywall or other outer surface of the existing structural wall, and tile or other outer finished material is installed covering the membrane.
 13. An installation method of a shower base system against at least one existing structural wall, the method comprising; installing a shower base comprising a horizontal top floor surface and at least one standing sidewall corresponding to each existing structural wall; and installing a waterproof membrane prior to any final outer surface material.
 14. The method of installing a shower base system as claimed in claim 13, wherein the at least one standing sidewall is integrally formed with and substantially perpendicular to the shower base.
 15. The method of installing a shower base system as claimed in claim 13, wherein the at least one standing sidewall is tapered in profile from a bottom to a top thereof.
 16. The method of installing a shower base system as claimed in claim 13, wherein the shower base and, commensurately, at least one standing sidewall, being integrally formed therewith, comprise a composite polyurethane material or other suitably flexible, waterproof material.
 17. The method of installing a shower base system as claimed in claim 13, wherein when the system is installed against two or more contiguous existing structural walls, corresponding contiguous standing sidewalls are confluent at a seamless integrally formed corner.
 18. The method of installing a shower base system as claimed in claim 13, wherein the at least one standing sidewall is of a height sufficient to prevent water rising by capillary action from migrating into the surrounding structures.
 19. The method of installing a shower base system as claimed in claim 13, wherein the waterproof membrane is installed from the horizontal top floor surface of the shower base and continues upwardly along each standing sidewall and upwardly along the corresponding structural wall.
 20. The method of installing a shower base system as claimed in claim 13, wherein the waterproof membrane is installed from a position partway up each standing sidewall and upwardly along the corresponding structural wall.
 21. The method of installing a shower base system as claimed in claim 13, wherein the waterproof membrane comprises a bitumen-like skin with embedded texturing, applied with adhesive and enhanced by priming the surface to be covered.
 22. The method of installing a shower base system as claimed in claim 13, wherein the waterproof membrane extends upwardly to the top of the shower enclosure.
 23. The method of installing a shower base system as claimed in claim 13, wherein the shower base is installed directly abutting drywall or other outer surface of an existing structural wall, the waterproof membrane is installed from a position partway up each corresponding standing sidewall and upwardly along the existing structural wall, adhering intimately to the standing sidewall and drywall or other outer surface of the existing structural wall, and tile or other outer finished material is installed covering the membrane.
 24. The method of installing a shower base system as claimed in claim 13, wherein the shower base is installed directly abutting a bottom plate and studs or timbers of an existing structural wall, with drywall or other outer surface of the structural wall installed over the corresponding standing sidewall, the waterproof membrane is installed from the horizontal top floor surface of the shower base and continues upwardly along the structural wall, adhering intimately to the horizontal top floor surface and drywall or other outer surface of the existing structural wall, and tile or other outer finished material is installed covering the membrane. 